Technical Article

High-Performance
Spherical Roller Bearings:
Meeting Today’s Greater Demands

Authors: John Rhodes, Senior Product Development Engineer and Karen Clever, Product Manager - Spherical Roller Bearings
Table of Contents:
Market Demands 2 High-Performance Spherical Roller Bearings:
The Case for Meeting Today’s Greater Demands
Spherical Roller Bearings 2
High-Performance
Parameters 4 • A stronger response to the tougher requirements
of heavy machines and equipment
Key Design Elements 5
• New high-performance bearing design aims at elevated load, speed and
Design Validation 8 temperature needs

• Continuous improvements, including no central guide ring, reduced

The Timken Difference 14 friction, torque; improving efficiency
References 15
• Demonstrated load rating increase; testing shows lower operating
temperatures, longer life vs. leading designs

Abstract
Spherical roller bearings provide for precise, repeatable motion and reliable
extended operation in the world’s most demanding industrial applications.
Timken® High-Performance Spherical Roller Bearings were designed as
a stronger response to today’s tougher environments and the increasing
requirements of heavy industry.

This paper explores new expectations for key applications, advances

in spherical roller bearing technology, and the design and testing
of Timken high-performance spherical roller bearings, which meet published
data for increased dynamic load rating and superior thermal performance
compared to previous designs.
 High-Performance Spherical Roller Bearings:
2 Meeting Today’s Greater Demand

Market Demands
Today, industry expectations push the limits of durability and production in
heavy industry, putting traditional machine and component designs to the
test. The global marketplace demands greater reliability at higher operating
temperatures, loading and speeds, emphasizing increased efficiency
every step of the way. For many, opportunity will come from incremental
improvements to existing technologies rather than major advances—logic
evidenced in the design ofTimken high-performance spherical roller bearings.

As oil producers drill deeper and further offshore, as paper mills commission
bigger and faster machines, as mining operations grow more remote and
as construction faces more punishing conditions, plant and equipment
operators increasingly look to suppliers and manufacturers to generate new
operational efficiencies. Across industries, the goal is measurable gains in
performance, productivity and profitability resulting from improvements to
existing systems, processes and assets.

Timken, which has offered spherical roller bearings for more

than 70 years, launched an intensive continuous improvement effort aimed
to outpace escalating load, speed and temperature requirements for bearings
operating in critical applications.

The Case for Spherical Roller Bearings

Spherical roller bearings are a special class of roller bearings, counted on
Figure 1: in many of the most difficult, demanding applications. These self-aligning,
Due to the spherical shape of the
outer ring geometry, spherical double-row radial bearings are designed with an inner and outer ring and
roller bearings can maintain full “barrel” shaped rollers separated by a cage, allowing for greater load-
bearing capacity with as much as carrying capacity and dynamic angular misalignment ability compared to
2° of misalignment produced by a
other common bearing types, including tapered and cylindrical.
combination of initial component
alignment and dynamic deflections;
their contact geometry also Most bearings are intended to carry either a radial load (acts perpendicular
eliminates edge loading typical of to the shaft) or axial load (also called thrust load; acts parallel to the shaft).
other bearing types.
Spherical roller bearings, however, must tolerate combined loads where
moderate-to-high radial and axial forces are at work (Figure 1).

Spherical roller bearings are used not only where shaft misalignments are
common, but where contamination, shock and vibration also are constant
challenges. Their robust design and higher tolerance for misalignment are
especially suited to heavy machinery, industrial equipment and large gearboxes.
Typical markets and applications include:
 High-Performance Spherical Roller Bearings:
3 Meeting Today’s Greater Demand

• Pulp & Paper (chippers/debarkers, calendar rolls, internal suction rolls,

press rolls, dryers)

• Power Transmission (hoists/cranes, pumps, compressors, wheels,

sheaves, winches, conveyors)

• Gear Drives/Gearboxes (high speed, marine, wind energy, general

industrial)

• Metals (caster rolls, drives, pinion stands, crop shear drives)

• Cement/Aggregate (vertical rolling mills, jaw/impact crushers, vibrating

screens, conveyors)

• Construction/Mining (shovels, trenchers, draglines, excavators, crushers,

compactors, shearers)

• Power Gen – Coal (pulverizers, gear drives, pumps, draft fans, conveyors)

• Oil/Gas (mud pumps, drawworks, jackup drives)

• Sugar (mills, dryers, coolers, vibrating/rotary screens, pumps)

• Other (ropeways, presses, elevators, pellet mills, harvesters, shredders,

wood cutters)

High-Performance Parameters
“High performance” relative to spherical roller bearings is described as
an increase in bearing service life, which allows the potential to downsize
other component selections while maintaining current levels of system
performance (that is, smaller equipment and systems working more
efficiently/effectively; increased power density translating to greater power
throughput and longer system life).

High performance is also described as a reduction in heat generation;

bearings that function at lower temperatures under demanding conditions
create the potential for increased efficiency and speeds of operation. Lower
temperatures reduce the oxidation rate and deterioration of oils, greases
and films, extending lubrication and thus, bearing service life.

While the basic functionality of today’s spherical roller bearings remains

fundamentally similar to that introduced in the 1950s, continuous
improvements to performance have been a focal point for bearing
manufacturers.The research and development effort fromTimken progressed
with the market to exceed the growing size and power requirements of heavy
machinery and gear-driven equipment.
 High-Performance Spherical Roller Bearings:
4 Meeting Today’s Greater Demand

Key Design Elements

Objectives for design optimization of the Timken spherical roller bearing
(Figure 2) included: 1) greater load-carrying capability, 2) reduced operating
temperature and 3) extended service life. Specifically, activities were focused
around: 1) optimizing internal geometries to maximize roller length and
dynamic capacity, 2) improving surface finishes to support higher ratings
and increased lubrication lambda ratios, 3) strengthening cage design to
reduce wear, 4) enhancing lubrication flow to rolling contact surfaces, and 5)
improving heat dissipation.

As a standard element of any continuous improvement endeavor, Timken

Figure 2: also set out to reduce design complexity where the potential for simpler and/
The Timken high-performance or fewer components was presented.
spherical roller bearing.
The design of the new high-performance bearing follows the ISO standard
for bearing boundary dimensions (inner diameter [I.D.], outer diameter [O.D.]
and width), allowing for general interchangeability with other manufacturers.
The standard does not, however, dictate cage design or internal geometry,
which is where Timken high-performance spherical roller bearings derive
their differentiated performance advantages.

Internal geometry
At the heart of spherical roller bearing design is the inner ring geometry
(Figure 3), requiring both precise design specification and manufacturing
consistency. The inner ring allows a complex interaction between the bearing
contact angle and raceway profile1, which must be specified to achieve the
optimal combination of size and form to produce the most efficient raceway-
roller dynamics (Figure 4).

Timken extended the demonstrated high-performance parameters of

the Timken P900 tapered roller bearing—which has shown service life
improvements in strenuous applications for nearly 20 years2 to the new
spherical design. P900 relies on optimized geometries, special finishes
and high-quality materials to achieve an increased power density (bearing
capacity to weight ratio) to provide a more efficient solution3-5.

Specifically, advanced geometry virtually eliminates edge stress

concentrations caused by high loads or misalignment. The macro raceway
profile contact geometry was improved to minimize the opportunity to
develop conditions where contact stresses are concentrated at one location
Figure 3:
Spherical roller bearing inner ring
geometry
 High-Performance Spherical Roller Bearings:
5 Meeting Today’s Greater Demand

thereby greatly reducing rolling contact fatigue life. Timken employs a multi-
tiered method of assessing profiles. Figure 4a provides a typical result for a
raceway profile trace assessment, relative to the high-performance design
intent envelope depicted by the bold radii. Figure 4b predicts contact stress
results for a profile trace versus the nominal design intent. Given the stress
peaks that would result in premature life predictions, this profile would not
be acceptable.
Figure 4:
High-performance spherical roller
bearing component explosion The micro raceway texture was also improved by reducing the composite
highlighting inner ring. surface roughness. This has a direct effect on increasing the operating
lambda (λ) ratio (Figure 5), where lambda equals the predicted operating oil

Figure 4a:
Raceway profile gauge envelope.

Figure 4b:
Stress profile assessment.
 High-Performance Spherical Roller Bearings:
6 Meeting Today’s Greater Demand

film thickness divided by the composite surface roughness. Improvement

in lambda ratio has been well documented to increase bearing fatigue
life predictions, as represented by a3l factor increase in factor-based life
calculations6-8. Specifications on micro texture were employed beyond those
associated with composite roughness to ensure the desired lambda ratio is
achieved in operation.The improvement in surface texture also sets the stage
for potential reduced heat generation by allowing the selection of reduced
viscosity lubricants that still meet adequate operating lambda ratios.

Cage construction
Cages (also called retainers) serve several purposes in the proper operation
of a rolling element bearing, including separating the rolling elements
Figure 5: to prevent roller-on-roller contact and wear. Cages also align the rolling
Lubrication lambda ratio improvement. elements on the inner ring outside the operating load zone to minimize roller
sliding, skidding and skewing.

An advanced cage design methodology was incorporated into the Timken

high-performance spherical roller bearing, resulting in the Timken EJ steel
cage (Figures 6 & 7). At elevated speeds, a steel cage provides an advantage
over brass due to its lower mass and reduced roller/cage contact. The EJ
cage is also nitrided (surface hardened) for improved wear resistance and
fatigue strength.

The new design incorporates the same positive aspects of existing Timken
steel cages, including inner ring piloting, low mass, low inertia, an individual
cage for each row, no separate center ring for roller axial positioning and
introduces slots in the outboard face of the cage (Figure 6). The symmetrical
openings are oriented between the cage pockets to facilitate lubricant flow in
Figure 6: and out of the inner ring raceway. This helps to assure lubricant availability
Timken high-performance EJ assembly.
to these rolling contact surfaces to generate a satisfactory film while further
reducing the potential for extreme heat due to viscous shear from excessive
lubricant supply.

Cage guidance
The EJ design includes two independent cages (one for each row of rollers),
which are assembled into an individual bearing.This allows each path of cage
and rollers to operate independently. The window-style pocket construction
reduces bending stresses. The cage is guided on the inner ring (opposed to
roller guidance, which transitions loads to the rollers, generating more heat)
and runs above pitch. This increases cage stiffness and reduces stress under
high shock load or acceleration.
Figure 7:
EJ steel cage.
 High-Performance Spherical Roller Bearings:
7 Meeting Today’s Greater Demand

Figure 8:
Large EJ steel cage.

For bearings with an O.D. greater than 400 mm, the cage and roller mass can become substantial and negatively
impact bearing heat generation and operating temperatures. To counter this, the bore of larger EJ steel cages is
specifically profiled to minimize friction and associated heat generation from contact with the inner ring pilot surface.

Roller guidance
Rollers are guided by the edges of the cage pocket for smaller bearings (<400 mm O.D.). For larger sizes, the pocket
is contoured with four pads (strategically located on the bridge surface) that contact and orient the rollers coming
into and out of the bearing operating load zone. This interaction minimizes potential for negative roller skew and its
associated increase in friction torque and operating temperature (Figure 8).

No central guide ring

Given these precise cage pocket interactions, a central guide ring is not required to axially position the rollers in the
EJ design. Without a guide ring, the friction generated between the rollers and ring is eliminated, equating to cooler
running bearings. Less friction also means less energy is needed to move the bearing initially and to keep it moving.

Eliminating the guide ring further creates extra space within the design envelope to accommodate longer rollers,
meaning increased load capacity. Alternatively, lubricant flow between the roller paths is improved by increasing
available void volume.

Thus, the EJ cage pocket design can translate to reduced bearing operating temperature and running torque in
applications where central ring-guided spherical roller bearings are currently used.

Note: Roller/cage interface design optimization was also performed on Timken brass cage offerings (EM and EMB). Brass cages
are more resistant to extreme loads and shock (meeting the demands of vibrating screen and high-speed planetary gearbox
applications, for example). They are also suited for low-lubrication conditions due to the dissimilar material of the rollers and
cage. Cage fingers provide constant, precise roller guidance.
 High-Performance Spherical Roller Bearings:
8 Meeting Today’s Greater Demand

Design Validation
Validation of the Timken high-performance spherical roller Bearing design was extensive in order to meet the
stringent requirements of Timken brand products. This included standardized fatigue life testing to confirm durability
under strenuous and accelerated operating conditions, as well as testing on different platforms to verify bearing
heat generation response as measured by outer-ring temperature. An assessment of competitive high-performance
products was also completed, and the results compared to the Timken high-performance spherical roller earing.
Specifically, testing sought to: 1) Substantiate an increased dynamic load and thermal speed rating over previous
Timken spherical roller bearings and 2) Validate a lower operating temperature and longer service life compared to
other leading high-performance designs.

Methodology and modeling

Timken standard life testing is completed in a first-in-four arrangement (Figure 9). The bearings are tested under an
elevated load and speed condition using a circulating oil lubrication system that controls the inlet oil temperature to
a specified elevated level. The intent is to test the bearing rolling contact surfaces in an accelerated manner relative
to surface and subsurface fatigue modes. The influence of bearing design, material, heat treatment, geometry,
surface profile and texture have a combined impact on life testing with the first-in-four format used to develop the
test Weibull statistics.

Timken SYBER analytical modeling software is used to establish the predicted bearing performance based on the
bearing metrology and test conditions. Test results are evaluated using Weibull statistics regarding L15.91 life and
the associated 65 percent confidence bands to establish test performance. The Weibull result is then compared to
the SYBER predictions, and an assessment is made regarding acceptability of the resultant life ratio. These ratios are
reviewed to determine their degree of support for intended rating performance levels.

Figure 9:
SYBER modeling of life test
arrangement.
 High-Performance Spherical Roller Bearings:
9 Meeting Today’s Greater Demand

Life testing
Validation life testing consisted of a number of bearing test populations spread across four basic size and series
designs. For each, individual groups of a minimum of 24 bearings were run using the accelerated testing format.
Multiple groups were run for each size, and in total, 27 groups (more than 592 individual bearings) were tested as
summarized in Table 1. Monitored parameters included vibration, temperature, torque, bearing condition and duration.

For each of the four spherical roller bearing series tested, SYBER was used to establish predicted life for given
conditions. The Weibull results were then divided by the SYBER predicted fully adjusted lives, with a dynamic load
rating calculated per ISO 2819 to produce the ISO Life Test Ratios (summarized in Figure 10). A Life Test Ratio of 1
indicates product performance barely supports the prediction when a basic ISO 281 dynamic load rating is used.
It can be seen here that all groups’ Life Ratios exceed 2.5, and the LCL65 limits exceed 2 for all conditions. This
is required if the product is to be deemed “high performing” with an associated increased dynamic load rating.
Testing sought to substantiate product performance and produce data to support an increased dynamic load
rating. Figure 11 shows the High-Performance Life Test Ratio after the bearing dynamic load rating is increased, this
time using the Timken rating methodology2; 10 as the base. It can be seen that all Life Ratios are greater than 1, and
most are 2 or more. The lower confidence bands are also significantly greater than 1, indicating high confidence
in an increased load rating of this magnitude.

Competitive life testing

The validation plan also included a competitive benchmarking component. Three top-tier spherical roller
bearing designs were selected for comparative testing (for each, the competitor’s explicitly stated “high
performance” offering was chosen). A life test program consistent with bearing size 22212 was completed
and the results compared (Figure 12). The competitive life ratio was established by dividing the life test
results of the individual group by that of the Timken results.

Table 1:
Life and Durability Testing.
 High-Performance Spherical Roller Bearings:
10 Meeting Today’s Greater Demand

Figure 10:
ISO Life Test Ratio for four basic test
group sizes.

Figure 11:
High-Performance Life Test Ratio for four
basic test group sizes.

Figure 12:
Competitive Life Testing for 22212.
 High-Performance Spherical Roller Bearings:
11 Meeting Today’s Greater Demand

Each of the competitive products was assigned an enhanced dynamic load rating compared to ISO 281
calculations9. As shown in Figure 12, it is clear that not all spherical roller bearings categorized as “high-
performance” perform to the same level. All competitor life ratios are less than 1, and assessment of
the 65 percent confidence bands indicates statistically significant differences between some competitive
designs and the corresponding Timken design. The larger size of the bands also indicates greater variation
in the populations for the competitive products.

Heat generation testing

Figure 13 shows the results if this same life test data is evaluated from a thermal perspective via
operating temperatures. The outer ring O.D. temperature was continuously monitored for each bearing
during operation. Of note is the difference or “delta” between the inlet oil temperature and bearing O.D.
temperature. The Timken high-performance spherical roller bearing consistently operates with the lowest
average temperature and has the smallest standard deviation. This is consistent with reduced operating
variation and reduced likelihood of elevated operating temperatures, which can dramatically impact
bearing life due to reduced lubrication lambda ratios.

A second aim of heat generation testing was to assess the life test arrangement with a combined radial
and axial load condition. Radial loads were applied in the conventional manner through the center
bearings, while axial loads were applied to the end of the outboard bearing housings. This produces a
combined radial and axial loading condition on the outboard end bearing positions, and maintains a pure
radial load on the center bearings.

Figure 13: Average Delta Std Dev

Life test operating temperature 12
comparison.
10

6
Temperature (deg C)

Timken High- Competitor “A” Competitor “B” Competitor “C”

Performance EJ
 High-Performance Spherical Roller Bearings:
12 Meeting Today’s Greater Demand

The test matrix (Table 2) consists of three different load levels (defined by increasing the radial equivalent
load to decrease the capacity to load ratio), with four combinations of axial to radial load ratio (producing
the same radial equivalent load). Each bearing arrangement was operated through four increasing speed
conditions (1200, 2400, 3600 and 4800 rpm) for each of the 12 load steps. This combined matrix produced
48 load and speed steps for assessment of bearing operating temperature.

Table 2:
22212 Combined load
heat generation test plan.

The bearings were lubricated by a circulating oil system, providing a nominal 0.95 l/min oil flow per
bearing, and the 37.85 liter oil sump was allowed to seek its own stabilized temperature based on total
system heat generation. The system was allowed to operate until thermal equilibrium was obtained,
based on stabilized operating temperatures. The results for average O.D. temperature are summarized
in Figure 14.

Figure 14:
Combined load test temperature results,
end and center bearings.
 High-Performance Spherical Roller Bearings:
13 Meeting Today’s Greater Demand

The Timken hgh-performance spherical roller bearing produced superior results while operating the
coolest for the demanding combined load end positions. Consistent with the life test temperature results,
Competitor B produced the highest operating temperatures, while Competitor C experienced particularly
elevated temperatures for the center bearing positions. Thus, the test suggests longer service life for the
Timken bearing as a result of reduced operating temperatures.

Vibratory screen testing

The final intent of the heat generation assessment was to validate operation on a vibrating screen platform.
A horizontal test unit utilizing a two-shaft, four-bearing arrangement was operated at 865 RPM, which
produced an inertial loading of 10 g-force. The unit was operated in its design splash lubrication scheme
using Mobil Spartan EP 150 gear oil, and system thermal response was monitored during 400 hours of
operation. Figure 15 provides a graphical comparison for the Timken high-performance spherical roller
Bearing compared to competitor designs.

As confirmed by infrared thermography (Figure 16), distinctive temperature profiles develop during the
test. The operating pattern for the Timken bearing is shown compared to a competitive arrangement.

Figure 15:
Bearing O.D. temperature comparison
for vibratory testing.

Figure 16:
Infrared thermography of vibratory
testing.

Graphic representation of thermographic readings in a typical industrial setting based on actual test results.
 High-Performance Spherical Roller Bearings:
14 Meeting Today’s Greater Demand

There is a clear and substantial difference, translating to cooler

operation with the associated improvements in predicted bearing
and lubrication service life.

The Timken Difference

Validation results were consistent and conclusive; the Timken high-
Figure 17: performance spherical roller bearing achieved its performance
Load rating comparison – average of 222 targets. An increased dynamic load rating of 18 percent was
series. substantiated (Figure 17), and a 17 percent thermal speed rating
increase confirmed (Figure 18), relative to previous Timken spherical
roller bearing designs.

Side-by-side application testing under identical loads, speeds and

lubrication conditions further showed the Timken bearing achieved
a longer calculated life and ran between 3° C and 8° C cooler than
leading competitive high-performance designs (Figure 19). Of
significance to machine and equipment owners and operators is that
Figure 18: a 5° C decrease in operating temperature can equate to a 9 percent
Thermal speed rating comparison – increase in bearing service life.
average of 222 series.

The results validate a high-performance spherical roller bearing

design that is ready to meet the escalating load, speed and
temperature requirements of heavy duty industrial machines and
equipment. Ultimately it is efficient, reliable performance that
equates to increased uptime and lower operating costs in the world’s
most demanding applications and environments.

Figure 19: 100°C

212°F
The Timken bearing demonstrated a
Average Bearing O.D. Temperature

lower operating temperature and longer

95°C Competitor A
life compared to competitive designs. 203°F
91°C (195.8°F)
Competitor C
94°C (201.2°F)
90°C
194°F

Competitor B
85°C 89°C (192.2°F) Timken
185°F 86°C (186.8°F)
Target L10
80°C Calculated Life
176°F

0 0.5 1 1.5 2 2.5

Life Ratio
Tested 22212 at 2700 rpm with a load ~25% of the dynamic capacity.
 High-Performance Spherical Roller Bearings:
15 Meeting Today’s Greater Demand

For any product to be backed by the Timken brand, the test results
must be substantiated for all involved production supply chains, and
quality manufacturing processes capable of consistently achieving
high performance must be demonstrated. This was accomplished
by multiple-year evaluations of the total Timken high-performance
spherical roller bearing supply chain, which confirmed that
specifications and procedures are in place to ensure production will
support the Timken brand promise.

References
1. Harris, T.A. and Kotzalas, M.N. (2007), Rolling Bearing Analysis, 5th
Ed – Advanced Concepts of Bearing Technology, CRC Press, Boca
Raton.

2. Moyer, C.A., Nixon, H.P. and Bhatia, R.R. (1988), “Tapered Roller
Bearing Performance for the 1990’s,” SAE Paper #881232, SAE
International, Warrendale.

3. Stover, J.D., Kolarik, R.V. and Keener, D.M. (1990), “The Detection of
Aluminum Oxide Stringers in Steel Using an Ultrasonic Measuring
Method,” Proc. 31st Mechanical Working and Steel Processing
Conference, p. 431-440.

4. Hoeprich, M.R. (1985), “Numerical Procedure for Designing Rolling

Element Contact Geometry as a Function of Load Cycle,” SAE Paper
#850764, SAE International, Warrendale.

5. Moyer, C.A. and Bahney, L.L. (1990), “Modifying the Lambda Ratio
to Functional Line Contacts,” STLE Tribology Transactions, v. 33, n.
4, p. 535-542.

6. Danner, C. H. (1970), “Fatigue Life of Tapered Roller Bearings under

Minimal Lubricant Films,” ASLE Transactions, v. 13, n. 4, p. 241-251.

7. Zaretsky, E.V. ed. (1971), Life Adjustment Factors for Ball and Roller
Bearings, An Engineering Design Guide, ASME, New York.

8. Zhou, R.S. (1993), “Surface Topography and Fatigue Life of Rolling

Contact Bearings,” STLE Tribology Transactions, v. 36, n. 3, p. 329-
340.

9. ISO 281 (2007), Rolling Bearings – Dynamic Load Ratings and Rating
Life. International Organization for Standardization, Geneva.

10. Dominik, W. K. (1984), “Rating and Life Formulas for Tapered Roller
Bearings,” SAE Paper #841121, SAE International, Warrendale.

11-15 :29 TKN High Performance SRB Technical White Paper | Timken ® is a registered trademark of The Timken Company. | © 2015 The Timken Company | Printed in U.S.A.